EP1809460A1 - Light-weight sound-absorbing covering for a body part of a motor vehicle and method for producing the same - Google Patents

Light-weight sound-absorbing covering for a body part of a motor vehicle and method for producing the same

Info

Publication number
EP1809460A1
EP1809460A1 EP05810923A EP05810923A EP1809460A1 EP 1809460 A1 EP1809460 A1 EP 1809460A1 EP 05810923 A EP05810923 A EP 05810923A EP 05810923 A EP05810923 A EP 05810923A EP 1809460 A1 EP1809460 A1 EP 1809460A1
Authority
EP
European Patent Office
Prior art keywords
sound
insulation layer
absorbing layer
polyurethane foam
sound insulation
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP05810923A
Other languages
German (de)
French (fr)
Other versions
EP1809460B1 (en
Inventor
Dirk Soltau
Michael Hansen
Paul SCHÖNZART
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Carcoustics Techconsult GmbH
Original Assignee
Carcoustics Techconsult GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Carcoustics Techconsult GmbH filed Critical Carcoustics Techconsult GmbH
Publication of EP1809460A1 publication Critical patent/EP1809460A1/en
Application granted granted Critical
Publication of EP1809460B1 publication Critical patent/EP1809460B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/129—Enhancing adhesion to the preformed part using an interlayer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/08—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles using several expanding or moulding steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/08—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles using several expanding or moulding steps
    • B29C44/083—Increasing the size of the cavity after a first part has foamed, e.g. substituting one mould part with another
    • B29C44/086—Increasing the size of the cavity after a first part has foamed, e.g. substituting one mould part with another and feeding more material into the enlarged cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22—After-treatment of expandable particles; Forming foamed products
    • C08J9/228—Forming foamed products

Definitions

  • the invention relates to a method for producing a lightweight, sound-insulating cladding for a body part of a motor vehicle according to the Ober ⁇ concept of claim 1 and a light, sound-insulating cladding for a body part of a motor vehicle, in particular in the form of a Stirnwand ⁇ fairing, according to the preamble of claim 11.
  • Conventional end wall panels for motor vehicles are constructed of a sound-absorbing heavy layer and acting as an elastic spring of an acoustic spring-mass system foam or textile nonwoven layer.
  • the basis weight of such Stirnwand ⁇ covers is usually in the range above 2 kg / m 2 .
  • the spring-mass system consists of a layer of open-pored flexible polyurethane foam and a top layer of filled polyurethane foam.
  • the polyurethane foam is designed as IntegralWebum, has a Shore A hardness of 80 to 90 and contains an additional filler content of 400 up to 500% by weight. Both layers are joined together by back-foaming, wherein the cover layer is inserted into a mold and foamed with the flexible polyurethane foam behind.
  • polyurethane foam which consists of 50% commercial hard polyol (hydroxyl number about 300 to 600) and 50% commercial soft polyol ( Hydroxyl number about 40 to 60).
  • the present invention has for its object to provide a sound-absorbing and sound-absorbing panel, in particular a front wall paneling for motor vehicles, which has a low weight and can be realized with relatively low production costs. At the same time, a method for producing such a sound-insulating panel is to be specified.
  • a sound insulation layer of polyurethane foam with open-cell flexible polyurethane foam is foamed behind a sound-absorbing layer or a sound-absorbing layer of flexible polyurethane foam with polyurethane foam is backfoamed to form a sound insulation layer.
  • the inventive method is further characterized essentially in that the flexible polyurethane foam is produced from the same isocyanate material and the same polyol material as the polyurethane foam of Sound insulation layer, but with a different mixing ratio of isocyanate material and polyol material, wherein the weight fraction of the isocyanate material in the mixture for producing the sound insulation layer is set greater than in the mixture for producing the sound-absorbing layer, so that the sound insulation layer in the Substantially air-impermeable outer skin and a higher bulk density than the sound-absorbing layer produced.
  • the preparation according to the invention enables a cost saving, in particular in terms of plant technology.
  • a plant for the production erfindungs ⁇ according panels needed due to the erfindungs ⁇ modern reduction of the number of raw material components used a smaller number of parts of equipment, such as raw material reservoir, pipes, pumps, controls and other parts. Investment and operating costs can be saved.
  • there is the possibility of achieving volume discounts when purchasing the required raw material components since with the reduction of the Number of raw material components used is accompanied by a component-specific increase in quantity.
  • a preferred embodiment of the method according to the invention is characterized in that for the compaction of the polyurethane foam in the sound insulation layer, the mixing ratio for its preparation is adjusted so that 100 wt .-% polyol with about 60 to 70 wt .-%, preferably about 63 to 68 wt .-% isocyanate are mixed, whereas the mixing ratio for the produc- tion of the polyurethane flexible foam for the sound-absorbing layer is adjusted so that 100 wt .-% polyol with about 45 to 55 wt .-%, preferably about 48 to 53 wt .-% isocyanate are mixed.
  • CO 2 is added to the polyol or the mixture for producing the flexible polyurethane foam for the sound-absorbing layer.
  • the required amount of raw material material for the sound-absorbing layer or its density can be reduced.
  • a further advantageous embodiment of the method according to the invention is characterized in that one side of a flexible barrier film with the polyurethane foam forming the soundproofing layer and the other side of the barrier film with the flexible foam forming the sound-absorbing layer is back-foamed.
  • barrier foil leaves the use of release agent in the production of the layers of fiction, contemporary panel significantly reduce when the barrier film is used so that it takes over the function of the release agent at least partially.
  • the barrier film improves the sound-insulating effect of the panel according to the invention.
  • the barrier film is preferably also made of polyurethane, whereby the sorted recycling (recycling) of the lining according to the invention is simplified.
  • the cladding according to the invention has a formgeCum ⁇ te sound insulation layer of polyurethane foam and a form ⁇ foamed sound-absorbing layer of fenzelligem flexible polyurethane foam, wherein the sound insulation layer and the sound-absorbing layer are foamed together.
  • the sound insulation layer is made from the same isocyanate material and the same polyol material as the sound-absorbing layer, but with a different mixing ratio of isocyanate material and polyol material such that it has a higher bulk density and is harder than the sound-absorbing layer, wherein the sound insulation layer has a substantially air-impermeable outer skin.
  • the sound insulation layer forms a flexible sealing lip on the edge of the cladding.
  • the flexible sealing lip resembles any production Tolerances and thus ensures optimal adaptation of the panel to adjacent components or Karosseriewand ⁇ sections sure. As a result, the sound-insulating effect of the lining according to the invention is optimized.
  • the fastening elements may, for example, be clip-type cable holders, hose holders or the like.
  • the sleeve-shaped cable ducts serve for a sealed passage of cables and / or lines through the cladding.
  • Figure 1 is a sectional view of the front portion of a motor vehicle with a passenger compartment from the engine compartment separating end wall and an internally disposed end wall panel.
  • FIG. 2 shows an enlarged sectional view of the end wall lining according to FIG. 1;
  • FIG. 3 is a sectional view of a portion of a bulkhead lining according to a second embodiment;
  • FIG. 4 is an enlarged sectional view of a portion of a panel according to the invention.
  • FIG. 5 is an enlarged sectional view of a portion of a panel according to the invention according to a third embodiment
  • Fig. 7 is a sectional view of molds for
  • the sound-insulating cladding according to the invention is preferably designed as a passenger compartment-side end wall cladding 1 of a motor vehicle 2. However, it can in principle also be designed for sound-insulating cladding of other body parts of a motor vehicle 2.
  • the trim is adapted to the contour of an end wall 3 which separates the passenger compartment 4 from the engine compartment 5.
  • the panel 1 according to the invention is self-supporting and is characterized by a relatively low weight. Their total surface weight is less than 1000 g / m 2 , preferably less than 800 g / m 2 .
  • the cladding 1 is formed from a sound insulation layer 6 of highly compressed flexible polyurethane foam and a sound-absorbing layer 7 of open-cell flexible polyurethane foam, wherein the two layers 6, 7 by coagulation of Schalldämm ⁇ layer 6 are materially interconnected.
  • the sound insulation layer 6 is made of the same isocyanate material and the same polyol material as the sound-absorbing layer 7, but with a different mixing ratio of isocyanate material and polyol material. As a result of the different mixing ratio, the sound insulation layer 6 is harder and has a higher bulk density than the sound-absorbing layer 7.
  • the sound insulation layer 6 is compressed in such a way that it has a substantially air-impermeable outer skin 6.2 (compare FIGS. 4 and 5). It can therefore be sucked with vacuum cups and thus allows automated assembly of the panel. 1
  • the mixing ratio for producing the compacted flexible polyurethane foam layer is 100% by weight of polyol to about 60 to 70% by weight of isocyanate, preferably about 63 to 68% by weight of isocyanate, particularly preferably about 65% by weight. isocyanate.
  • the mixing ratio for the preparation of the polyurethane flexible foam for the sound-absorbing layer 7 is 100% by weight of polyol to about 45 to 55% by weight of isocyanate, preferably about 48 to 53% by weight, in particular about 50% by weight of isocyanate , Despite its comparatively high density, the sound insulation layer 6 is sufficiently flexible.
  • a preferred embodiment of the lining 1 according to the invention is that the sound insulation layer 6 forms a flexible sealing lip 8 at the edge of the lining 1.
  • the sealing lip 8 may extend along one or more edge portions or along the entire peripheral edge of the panel 1.
  • one or more fastening elements 9 can be integrally integrated on the sound insulation layer 6.
  • the fastening elements 9 are for example clamp-like in that they have two legs 9.1, 9.2 projecting on the outside of the sound insulation layer 6, which form an undercut recess 10 for the positive or clamping reception of cables or lines (not shown).
  • one or more sleeve-shaped cable bushings 11 may be integrally integrated on the sound insulation layer 6, which sections or recesses in the form of passage openings 12 in the sound-absorbing layer 7 are associated therewith.
  • the cable bushings 11 are preferably conical and have at their two ends at least two diametrically opposite lying axial slots (not shown), so that they can adapt to different diameters of cables or lines and these always include sealing.
  • the covering 1 according to the invention can be produced in such a way that the sound-deadening layer 6 is initially foam-molded in a cavity defined by a lower tool 13 and an upper tool 14 from a mixture containing polyol and isocyanate with the above-indicated mixing ratio (FIG. 6).
  • filler preferably in the form of barium sulphate and / or calcium carbonate, may also be added to the mixture for producing the soundproofing layer 6.
  • At least one of the forming tools 13, 14 is provided with a heating device (not shown), eg with electrical heating resistors integrated in the tool 13 and / or 14.
  • the mold temperature is controlled as a function of the mixing ratio of isocyanate material and polyol material so that the generated sound insulation layer 6 has a cellular core zone 6.1 and a substantially air-impermeable outer skin 6.2 (see Fig. 4).
  • the bulk density of the sound insulation layer 6 is in the range of 0.1 to 1.4 g / cm 3 , preferably in the range of 0.2 to 1.1 g / cm 3 .
  • the average thickness of the sound insulation layer 6 is, for example, in the range of 1.5 to 5 mm, in particular in the range of 2 to 4 mm.
  • the upper tool 14 is exchanged for another upper tool 14 ', which with the lower tool 13 and the Sound absorbing layer 6 still attached thereto delimits a new (further) cavity 15 (FIG. 7).
  • a polyol and isocyanate-containing mixture is injected to produce the sound-absorbing layer 7, wherein the layer 7 is made of the same isocyanate material and the same polyol material as the foam-backed sound insulation layer 6, but with a different Mixing ratio of isocyanate material and polyol material.
  • CO 2 is added to the polyol or the mixture for producing the sound-absorbing layer 7.
  • the bulk density of the sound absorbing layer 7 is in the range of 0.016 to 0.065 g / cm 3 , preferably in the range of 0.02 to 0.06 g / cm 3 . Due to the differing gross densities of sound insulation layer 6 and sound-absorbing layer 7 results in the transition of the layers 6, 7 an acoustic impedance jump, which is advantageous in terms of sound-insulating effect of the panel 1 according to the invention.
  • the thickness of the sound-absorbing layer 7 can be formed locally differently depending on the acoustic requirements (see in particular Fig. 7).
  • the thickness of the layer 7 is for example in the range of 10 to 30 mm.
  • the soundproofing layer 6 and the sound-absorbing layer 7 are instantaneous materially connected to each other, wherein first the sound insulation layer ⁇ was foamed and then the sound-absorbing layer 7 was produced by back-foaming the sound insulation layer 6.
  • FIG. 5 illustrates a variant in which the soundproofing layer 6 and the sound-absorbing layer 5 are foamed together with the interposition of a barrier film 17.
  • the barrier film 17 increases the soundproofing effect of the lining 1 according to the invention and improves the connection between sound insulation layer 6 and sound-absorbing layer 7.
  • the barrier film 17 is also made of polyurethane.
  • the production of a lining according to FIG. 5 can take place in such a way that the barrier film 17 is foamed back using the molding materials 13, 14 according to FIG. 6 with the material mixture forming the sound insulation layer 6.
  • a plurality of small suction openings open at the bottom of the upper tool 14, by means of which the barrier film 17 is held by suction on the upper tool 14.
  • the sound-absorbing layer 7 is then produced by using a different cavity, the upper tool 14 ', by foaming the barrier film 17, similar to that shown in FIG. 7.
  • the embodiment of the invention is not limited to the embodiments described above. Rather, various other variants are conceivable. Thus, for example, partially reinforcing ribs or the like may be integrally formed on the sound insulation layer 6.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Medicinal Chemistry (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

The invention relates to a light-weight sound-absorbing covering (1) for a body part of a motor vehicle, especially in the form of a front bulkhead covering, and to a method for producing such a covering. The covering (1) comprises a foam-molded sound-damping layer (6) from polyurethane foam and a foam-molded sound-absorbing layer (7) from an open-pore flexible polyurethane foam. The aim of the invention is to reduce the costs for producing a covering of the aforementioned kind. For this purpose, the sound-damping layer (6) is produced from the same isocyanate material and the same polyol material as the sound-absorbing layer (7), however, with a different proportion of isocyanate material to polyol material. The proportion is chosen in such a manner that the sound damping layer (6) has a higher bulk density and hardness than the sound-absorbing layer (7), the sound damping layer (6) having a substantially air-tight skin (6.2).

Description

MY/sa 040865WO 10. November 2005MY / sa 040865WO November 10, 2005
Leichte schallisolierende Verkleidung für einLightweight soundproof panel for one
Karosserieteil eines Kraftfahrzeuges undBody part of a motor vehicle and
Verfahren zu ihrer HerstellungProcess for their preparation
Die Erfindung betrifft ein Verfahren zur Herstellung einer leichten, schallisolierenden Verkleidung für ein Karosserieteil eines Kraftfahrzeuges gemäß dem Ober¬ begriff des Anspruchs 1 sowie eine leichte, schall¬ isolierende Verkleidung für ein Karosserieteil eines Kraftfahrzeuges, insbesondere in Form einer Stirnwand¬ verkleidung, gemäß dem Oberbegriff des Anspruchs 11.The invention relates to a method for producing a lightweight, sound-insulating cladding for a body part of a motor vehicle according to the Ober¬ concept of claim 1 and a light, sound-insulating cladding for a body part of a motor vehicle, in particular in the form of a Stirnwand¬ fairing, according to the preamble of claim 11.
Herkömmliche Stirnwandverkleidungen für Kraftfahrzeuge sind aus einer schalldämmenden Schwerschicht und einer als elastische Feder eines akustischen Feder-Masse- Systems wirkenden Schaumstoff- oder textilen Vlieslage aufgebaut. Das Flächengewicht derartiger Stirnwand¬ verkleidungen liegt üblicherweise im Bereich oberhalb von 2 kg/m2.Conventional end wall panels for motor vehicles are constructed of a sound-absorbing heavy layer and acting as an elastic spring of an acoustic spring-mass system foam or textile nonwoven layer. The basis weight of such Stirnwand¬ covers is usually in the range above 2 kg / m 2 .
Aus der DE 27 35 153 Al ist ein spezifisch leichtes, als Doppelmatte ausgebildetes Feder-Masse-System bekannt, das als Stirnwandverkleidung eines Kraftfahrzeuges vorgesehen ist. Das Feder-Masse-System besteht aus einer Schicht aus offenporigem Polyurethan-Weichschaum und einer Deckschicht aus gefülltem Polyurethan-Schwerschaum. Der Polyurethan-Schwerschäum ist als Integralschäum ausgeführt, weist eine Shore-Härte A von 80 bis 90 auf und enthält einen zusätzlichen Füllstoffanteil von 400 bis 500 Gew.-%. Beide Schichten sind durch Hinterschäumen miteinander verbunden, wobei die Deckschicht in eine Form eingelegt und mit dem Polyurethan-Weichschaum hinter¬ schäumt wird. Hinsichtlich der Realisierung des angegebe¬ nen Härtegrades der Deckschicht wird für die Herstellung des Polyurethan-Schwerschaums die Verwendung einer Polyolmischung vorgeschlagen, die zu 50% aus handels¬ üblichem Hartpolyol (Hydroxyl-Zahl etwa 300 bis 600) und zu 50% aus handelsüblichem Weichpolyol (Hydroxyl-Zahl etwa 40 bis 60) besteht.From DE 27 35 153 Al a specific light, designed as a double mat spring-mass system is known, which is provided as a front wall paneling of a motor vehicle. The spring-mass system consists of a layer of open-pored flexible polyurethane foam and a top layer of filled polyurethane foam. The polyurethane foam is designed as Integralschäum, has a Shore A hardness of 80 to 90 and contains an additional filler content of 400 up to 500% by weight. Both layers are joined together by back-foaming, wherein the cover layer is inserted into a mold and foamed with the flexible polyurethane foam behind. With regard to the realization of the indicated degree of hardness of the cover layer, the use of a polyol mixture is suggested for the production of polyurethane foam, which consists of 50% commercial hard polyol (hydroxyl number about 300 to 600) and 50% commercial soft polyol ( Hydroxyl number about 40 to 60).
Der vorliegenden Erfindung liegt die Aufgabe zugrunde, eine schalldämmende sowie schalldämpfende Verkleidung, insbesondere eine Stirnwandverkleidung für Kraftfahrzeuge bereitzustellen, die ein geringes Gewicht aufweist und sich mit relativ geringen Herstellungskosten realisieren lässt. Zugleich soll ein Verfahren zur Herstellung einer solchen schallisolierenden Verkleidung angegeben werden.The present invention has for its object to provide a sound-absorbing and sound-absorbing panel, in particular a front wall paneling for motor vehicles, which has a low weight and can be realized with relatively low production costs. At the same time, a method for producing such a sound-insulating panel is to be specified.
Hinsichtlich des Verfahrens wird diese Aufgabe erfindungsgemäß durch das Verfahren mit den Merkmalen des Anspruchs 1 gelöst.With regard to the method, this object is achieved by the method with the features of claim 1.
Bei dem erfindungsgemäßen Verfahren wird unter Verwendung eines Formwerkzeuges eine Schalldämmschicht aus Poly¬ urethanschaum mit offenzelligem Polyurethan-Weichschaum zur Ausbildung einer schallabsorbierenden Schicht hinter¬ schäumt oder eine schallabsorbierende Schicht aus Poly¬ urethan-Weichschaum mit Polyurethanschaum zur Ausbildung einer Schalldämmschicht hinterschäumt. Das erfindungs- gemäße Verfahren ist ferner im Wesentlichen dadurch gekennzeichnet, dass der Polyurethan-Weichschaum aus dem gleichen Isocyanat-Material und dem gleichen Polyol- Material erzeugt wird wie der Polyurethanschaum der Schalldämmschicht, jedoch mit unterschiedlichem Mischungsverhältnis von Isocyanat-Material und Polyol- Material, wobei der Gewichtsanteil des Isocyanat- Materials in der Mischung zur Herstellung der Schall¬ dämmschicht größer eingestellt wird als in der Mischung zur Herstellung der schallabsorbierenden Schicht, so dass die Schalldämmschicht eine im Wesentlichen luftundurch¬ lässige Außenhaut und eine höhere Rohdichte aufweist als die erzeugte schallabsorbierende Schicht.In the method according to the invention, a sound insulation layer of polyurethane foam with open-cell flexible polyurethane foam is foamed behind a sound-absorbing layer or a sound-absorbing layer of flexible polyurethane foam with polyurethane foam is backfoamed to form a sound insulation layer. The inventive method is further characterized essentially in that the flexible polyurethane foam is produced from the same isocyanate material and the same polyol material as the polyurethane foam of Sound insulation layer, but with a different mixing ratio of isocyanate material and polyol material, wherein the weight fraction of the isocyanate material in the mixture for producing the sound insulation layer is set greater than in the mixture for producing the sound-absorbing layer, so that the sound insulation layer in the Substantially air-impermeable outer skin and a higher bulk density than the sound-absorbing layer produced.
Mit dem erfindungsgemäßen Verfahren lassen sich besonders leichte schallisolierende Verkleidungen herstellen, die sowohl schalldämmend als auch schalldämpfend wirken. Die erhaltenen Verkleidungen reduzieren den Schallpegel im Fahrgastinnenraum erheblich und verbessern somit den Fahrkomfort des damit ausgerüsteten Kraftfahrzeuges. Andererseits erhöhen sie das Gewicht des Kraftfahrzeuges nur wenig, was für eine hohe Fahrleistung und einen niedrigen Kraftstoffverbrauch von Vorteil ist.With the method according to the invention, it is possible to produce particularly lightweight sound-insulating linings which have a sound-damping effect as well as a sound-damping effect. The resulting panels reduce the noise level in the passenger compartment considerably and thus improve the ride comfort of the thus equipped motor vehicle. On the other hand, they only slightly increase the weight of the motor vehicle, which is advantageous for high driving performance and low fuel consumption.
Die erfindungsgemäße Herstellungsweise, wonach der Poly¬ urethan-Weichschaum aus dem gleichen Isocyanat-Material und dem gleichen Polyol-Material erzeugt wird wie der Polyurethanschaum der Schalldämmschicht, ermöglicht eine Kosteneinsparung insbesondere in anlagentechnischer Hinsicht. Denn eine Anlage zur Herstellung erfindungs¬ gemäßer Verkleidungen benötigt aufgrund der erfindungs¬ gemäßen Reduzierung der Anzahl der verwendeten Rohstoff¬ komponenten eine geringere Anzahl von Anlagenteilen, wie Rohstoffvorratsbehälter, Leitungen, Pumpen, Steuerungen und andere Teile. Investitions- und Betriebskosten können dadurch eingespart werden. Ferner besteht die Möglich¬ keit, beim Einkauf der benötigten Rohstoffkomponenten Mengenrabatte zu erzielen, da mit der Reduzierung der Anzahl der verwendeten Rohstoffkomponenten eine komponentenspezifische Mengenerhöhung einhergeht.The preparation according to the invention, according to which the flexible polyurethane foam is produced from the same isocyanate material and the same polyol material as the polyurethane foam of the soundproofing layer, enables a cost saving, in particular in terms of plant technology. For a plant for the production erfindungs¬ according panels needed due to the erfindungs¬ modern reduction of the number of raw material components used a smaller number of parts of equipment, such as raw material reservoir, pipes, pumps, controls and other parts. Investment and operating costs can be saved. Furthermore, there is the possibility of achieving volume discounts when purchasing the required raw material components, since with the reduction of the Number of raw material components used is accompanied by a component-specific increase in quantity.
Eine bevorzugte Ausgestaltung des erfindungsgemäßen Verfahrens ist dadurch gekennzeichnet, dass zur Verdich¬ tung des Polyurethanschaums in der Schalldämmschicht das Mischungsverhältnis zu seiner Herstellung so eingestellt wird, dass 100 Gew.-% Polyol mit etwa 60 bis 70 Gew.-%, vorzugsweise etwa 63 bis 68 Gew.-% Isocyanat vermischt werden, wohingegen das Mischungsverhältnis zur Herstel¬ lung des Polyurethan-Weichschaums für die schallabsor¬ bierende Schicht so eingestellt wird, dass 100 Gew.-% Polyol mit etwa 45 bis 55 Gew.-%, vorzugsweise etwa 48 bis 53 Gew.-% Isocyanat vermischt werden.A preferred embodiment of the method according to the invention is characterized in that for the compaction of the polyurethane foam in the sound insulation layer, the mixing ratio for its preparation is adjusted so that 100 wt .-% polyol with about 60 to 70 wt .-%, preferably about 63 to 68 wt .-% isocyanate are mixed, whereas the mixing ratio for the produc- tion of the polyurethane flexible foam for the sound-absorbing layer is adjusted so that 100 wt .-% polyol with about 45 to 55 wt .-%, preferably about 48 to 53 wt .-% isocyanate are mixed.
Eine andere vorteilhafte Ausgestaltung des erfindungs¬ gemäßen Herstellungsverfahrens besteht darin, dass dem Polyol oder der Mischung zur Herstellung des Polyurethan- Weichschaums für die schallabsorbierende Schicht CO2 zugegeben wird. Hierdurch lässt sich die benötigte Menge an Rohstoffmaterial für die schallabsorbierende Schicht bzw. deren Rohdichte reduzieren.Another advantageous embodiment of the inventive manufacturing method is that CO 2 is added to the polyol or the mixture for producing the flexible polyurethane foam for the sound-absorbing layer. As a result, the required amount of raw material material for the sound-absorbing layer or its density can be reduced.
Eine weitere vorteilhafte Ausgestaltung des erfindungs¬ gemäßen Verfahrens ist dadurch gekennzeichnet, dass eine Seite einer flexiblen Sperrfolie mit dem die Schalldämm¬ schicht bildenden Polyurethanschaum und die andere Seite der Sperrfolie mit dem die schallabsorbierende Schicht bildenden Polyurethan-Weichschaum hinterschäumt wird.A further advantageous embodiment of the method according to the invention is characterized in that one side of a flexible barrier film with the polyurethane foam forming the soundproofing layer and the other side of the barrier film with the flexible foam forming the sound-absorbing layer is back-foamed.
Üblicherweise werden zum Formschäumen verwendete Formen mit einem das Entformen der Schaumformteile erleichtern¬ den Trennmittel eingesprüht. Mittels der Sperrfolie lässt sich der Einsatz von Trennmittel beim Herstellen der Schichten der erfindungs gemäßen Verkleidung erheblich reduzieren, wenn die Sperrfolie so eingesetzt wird, dass sie die Funktion des Trennmittels zumindest teilweise mit übernimmt . Zudem verbessert die Sperrfolie die schall- dämmende Wirkung der erfindungsgemäßen Verkleidung . Die Sperrfolie besteht vorzugsweise ebenfalls aus Polyurethan, wodurch die sortenreine Wiederverwertung (Recycling) der erfindungsgemäßen Verkleidung vereinfacht wird .Usually, molds used for mold foaming are sprayed with a mold releasing agent which facilitates mold removal. By means of the barrier foil leaves the use of release agent in the production of the layers of fiction, contemporary panel significantly reduce when the barrier film is used so that it takes over the function of the release agent at least partially. In addition, the barrier film improves the sound-insulating effect of the panel according to the invention. The barrier film is preferably also made of polyurethane, whereby the sorted recycling (recycling) of the lining according to the invention is simplified.
Hinsichtlich der schalldämmenden sowie schalldämpfenden Verkleidung wird die oben angegebene Aufgabe erfindungs¬ gemäß durch die Verkleidung mit den Merkmalen des Anspruchs 11 gelöst .With regard to the sound-absorbing and sound-damping cladding, the object stated above is achieved according to the invention by the cladding with the features of claim 11.
Die erfindungsgemäße Verkleidung weist eine formgeschäum¬ te Schalldämmschicht aus Polyurethanschaum und eine form¬ geschäumte schallabsorbierende Schicht aus of fenzelligem Polyurethan-Weichschaum auf , wobei die Schalldämmschicht und die schallabsorbierende Schicht aneinandergeschäumt sind . Die Schalldämmschicht ist aus dem gleichen Iso- cyanat-Material und dem gleichen Polyol-Material herge¬ stellt wie die schallabsorbierende Schicht, j edoch mit unterschiedlichem Mischungsverhältnis von Isocyanat- Material und Polyol-Material derart, dass sie eine höhere Rohdichte aufweist und härter ist als die schallabsor¬ bierende Schicht, wobei die Schalldämmschicht eine im Wesentlichen luftundurchlässige Außenhaut aufweist .The cladding according to the invention has a formgeschäum¬ te sound insulation layer of polyurethane foam and a form¬ foamed sound-absorbing layer of fenzelligem flexible polyurethane foam, wherein the sound insulation layer and the sound-absorbing layer are foamed together. The sound insulation layer is made from the same isocyanate material and the same polyol material as the sound-absorbing layer, but with a different mixing ratio of isocyanate material and polyol material such that it has a higher bulk density and is harder than the sound-absorbing layer, wherein the sound insulation layer has a substantially air-impermeable outer skin.
In einer bevorzugten Ausgestaltung der erfindungsgemäßen Verkleidung ist vorgesehen, dass die Schalldämmschicht am Rand der Verkleidung eine flexible Dichtlippe bildet . Die flexible Dichtlippe gleicht eventuelle Fertigungs- toleranzen aus und stellt so eine optimale Anpassung der Verkleidung an angrenzende Bauteile bzw. Karosseriewand¬ abschnitte sicher. Hierdurch wird die schalldämmende Wirkung der erfindungsgemäßen Verkleidung optimiert.In a preferred embodiment of the cladding according to the invention it is provided that the sound insulation layer forms a flexible sealing lip on the edge of the cladding. The flexible sealing lip resembles any production Tolerances and thus ensures optimal adaptation of the panel to adjacent components or Karosseriewand¬ sections sure. As a result, the sound-insulating effect of the lining according to the invention is optimized.
Eine andere vorteilhafte Ausgestaltung der erfindungs¬ gemäßen Verkleidung sieht vor, dass an der Schalldämm¬ schicht ein oder mehrere Befestigungselemente und/oder eine oder mehrere tüllenförmige Kabeldurchführungen einstückig integriert sind. Bei den Befestigungselementen kann es sich beispielsweise um klammerartiger Kabel¬ halter, Schlauchhalter oder dergleichen handeln. Durch die Integration solcher Befestigungselemente an der Schalldämmschicht lassen sich gegebenenfalls der Arbeits¬ aufwand und somit die Kosten für eine Montage entspre¬ chender Leitungen reduzieren. Die tüllenförmigen Kabel¬ durchführungen dienen einer abgedichteten Durchführung von Kabeln und/oder Leitungen durch die Verkleidung.Another advantageous embodiment of the inventive cover provides that one or more fastening elements and / or one or more sleeve-shaped cable bushings are integrally integrated on the sound insulation layer. The fastening elements may, for example, be clip-type cable holders, hose holders or the like. By integrating such fastening elements on the sound insulation layer, it is possible, if necessary, to reduce the workload and thus the costs for installing corresponding lines. The sleeve-shaped cable ducts serve for a sealed passage of cables and / or lines through the cladding.
Weitere bevorzugte und vorteilhafte Ausgestaltungen der erfindungsgemäßen Verkleidung und des Verfahrens zu ihrer Herstellung sind in den Unteransprüchen angegeben.Further preferred and advantageous embodiments of the lining according to the invention and the method for their preparation are specified in the subclaims.
Nachfolgend wird die Erfindung anhand einer mehrere Ausführungsbeispiele darstellenden Zeichnung näher erläutert. Es zeigen schematisch:The invention will be explained in more detail with reference to a drawing illustrating several embodiments. They show schematically:
Fig. 1 eine Schnittansicht des vorderen Abschnitts eines Kraftfahrzeuges mit einer den Fahrgastraum vom Motorraum trennenden Stirnwand und einer innenseitig angeordneten Stirnwandverkleidung;Figure 1 is a sectional view of the front portion of a motor vehicle with a passenger compartment from the engine compartment separating end wall and an internally disposed end wall panel.
Fig. 2 eine vergrößerte Schnittansicht der Stirnwand¬ verkleidung gemäß Fig. 1; Fig. 3 eine Schnittansicht eines Abschnitts einer Stirnwandverkleidung gemäß einem zweiten Ausführungsbeispiel;FIG. 2 shows an enlarged sectional view of the end wall lining according to FIG. 1; FIG. 3 is a sectional view of a portion of a bulkhead lining according to a second embodiment;
Fig. 4 eine vergrößerte Schnittansicht eines Abschnitts einer erfindungsgemäßen Verkleidung;4 is an enlarged sectional view of a portion of a panel according to the invention;
Fig. 5 eine vergrößerte Schnittansicht eines Abschnitts einer erfindungsgemäßen Verkleidung gemäß einem dritten Ausführungsbeispiel;5 is an enlarged sectional view of a portion of a panel according to the invention according to a third embodiment;
Fig. 6 eine Schnittansicht von Formwerkzeugen zur Herstellung einer Schalldämmschicht; und6 shows a sectional view of molds for producing a sound insulation layer; and
Fig. 7 eine Schnittansicht von Formwerkzeugen zumFig. 7 is a sectional view of molds for
Hinterschäumen einer gemäß Fig. 6 hergestellten Schalldämmschicht.Foaming of a soundproofing layer produced according to FIG. 6.
Die schallisolierende Verkleidung gemäß der Erfindung ist vorzugsweise als fahrgastraumseitige Stirnwandverkleidung 1 eines Kraftfahrzeuges 2 ausgebildet. Sie kann jedoch grundsätzlich auch zur schallisolierenden Verkleidung anderer Karosserieteile eines Kraftfahrzeuges 2 ausgebildet werden.The sound-insulating cladding according to the invention is preferably designed as a passenger compartment-side end wall cladding 1 of a motor vehicle 2. However, it can in principle also be designed for sound-insulating cladding of other body parts of a motor vehicle 2.
Wie in den Figuren 1 und 2 gezeigt, ist die Verkleidung der Kontur einer Stirnwand 3 angepasst, die den Fahrgast¬ raum 4 vom Motorraum 5 trennt. Die erfindungsgemäße Verkleidung 1 ist selbsttragend und zeichnet sich durch ein relativ geringes Gewicht aus. Ihr Gesamtflächen¬ gewicht beträgt weniger als 1000 g/m2, vorzugsweise weniger als 800 g/m2. Die Verkleidung 1 ist aus einer Schalldämmschicht 6 aus hoch verdichtetem Polyurethan-Weichschaum und einer schallabsorbierenden Schicht 7 aus offenzelligem Polyurethan-Weichschaum gebildet, wobei die beiden Schichten 6, 7 durch Hinterschäumung der Schalldämm¬ schicht 6 stoffschlüssig miteinander verbunden sind.As shown in FIGS. 1 and 2, the trim is adapted to the contour of an end wall 3 which separates the passenger compartment 4 from the engine compartment 5. The panel 1 according to the invention is self-supporting and is characterized by a relatively low weight. Their total surface weight is less than 1000 g / m 2 , preferably less than 800 g / m 2 . The cladding 1 is formed from a sound insulation layer 6 of highly compressed flexible polyurethane foam and a sound-absorbing layer 7 of open-cell flexible polyurethane foam, wherein the two layers 6, 7 by coagulation of Schalldämm¬ layer 6 are materially interconnected.
Erfindungsgemäß ist die Schalldämmschicht 6 aus dem gleichen Isocyanat-Material und dem gleichen Polyol- Material hergestellt wie die schallabsorbierende Schicht 7, jedoch mit einem unterschiedlichen Mischungsverhältnis von Isocyanat-Material und Polyol-Material. Infolge des unterschiedlichen Mischungsverhältnisses ist die Schall¬ dämmschicht 6 härter und weist eine höhere Rohdichte auf als die schallabsorbierende Schicht 7. Die Schalldämm¬ schicht 6 ist derart verdichtet, dass sie eine im Wesentlichen luftundurchlässige Außenhaut 6.2 aufweist (vgl. Figuren 4 und 5) . Sie kann daher mit Vakuumsaugern angesaugt werden und ermöglicht somit eine automatisierte Montage der Verkleidung 1.According to the invention, the sound insulation layer 6 is made of the same isocyanate material and the same polyol material as the sound-absorbing layer 7, but with a different mixing ratio of isocyanate material and polyol material. As a result of the different mixing ratio, the sound insulation layer 6 is harder and has a higher bulk density than the sound-absorbing layer 7. The sound insulation layer 6 is compressed in such a way that it has a substantially air-impermeable outer skin 6.2 (compare FIGS. 4 and 5). It can therefore be sucked with vacuum cups and thus allows automated assembly of the panel. 1
Das Mischungsverhältnis zur Herstellung der verdichteten Polyurethan-Weichschaumschicht (Schalldämmschicht 6) beträgt 100 Gew.-% Polyol zu etwa 60 bis 70 Gew.-% Isocyanat, vorzugsweise etwa 63 bis 68 Gew.-% Isocyanat, besonders bevorzugt etwa 65 Gew.-% Isocyanat.The mixing ratio for producing the compacted flexible polyurethane foam layer (sound deadening layer 6) is 100% by weight of polyol to about 60 to 70% by weight of isocyanate, preferably about 63 to 68% by weight of isocyanate, particularly preferably about 65% by weight. isocyanate.
Das Mischungsverhältnis zur Herstellung des Polyurethan- Weichschaums für die schallabsorbierende Schicht 7 beträgt hingegen 100 Gew.-% Polyol zu etwa 45 bis 55 Gew.-% Isocyanat, vorzugsweise etwa 48 bis 53 Gew.-%, insbesondere etwa 50 Gew.-% Isocyanat. Trotz ihrer vergleichsweise hohen Rohdichte ist die Schalldämmschicht 6 ausreichend flexibel. Wie insbesondere in den Figuren 2 und 3 gezeigt ist, besteht eine bevorzugte Ausgestaltung der erfindungsgemäßen Verkleidung 1 darin , dass die Schalldämmschicht 6 am Rand der Verkleidung 1 eine flexible Dichtlippe 8 bildet. Die Dichtlippe 8 kann entlang eines oder mehrerer Randabschnitte oder entlang des gesamten Umfangsrandes der Verkleidung 1 verlaufen.By contrast, the mixing ratio for the preparation of the polyurethane flexible foam for the sound-absorbing layer 7 is 100% by weight of polyol to about 45 to 55% by weight of isocyanate, preferably about 48 to 53% by weight, in particular about 50% by weight of isocyanate , Despite its comparatively high density, the sound insulation layer 6 is sufficiently flexible. As is shown in particular in FIGS. 2 and 3, a preferred embodiment of the lining 1 according to the invention is that the sound insulation layer 6 forms a flexible sealing lip 8 at the edge of the lining 1. The sealing lip 8 may extend along one or more edge portions or along the entire peripheral edge of the panel 1.
Mit einer derartigen Dichtlippe 8 lassen sich Toleranzen in der Bemessung angrenzender Einbau- und/oder Karosserieteile ausgleichen, so dass die mit der erfindungsgemäßen Verkleidung 1 erreichbare Schalldämm¬ wirkung optimiert ist.With such a sealing lip 8, tolerances in the dimensioning of adjacent installation and / or body parts can be compensated, so that the achievable with the panel 1 according to the invention Schalldämm¬ effect is optimized.
Wie in Fig. 3 ferner dargestellt ist, können an der Schalldämmschicht 6 ein oder mehrere Befestigungselemente 9 einstückig integriert sein. Die Befestigungselemente 9 sind beispielsweise klammerartige ausgebildet, indem sie zwei an der Außenseite der Schalldämmschicht 6 abstehende Schenkel 9.1, 9.2 aufweisen, die eine hinterschnitte Aus¬ nehmung 10 zur formschlüssigen bzw. klemmenden Aufnahme von Kabeln oder Leitungen (nicht gezeigt) bilden.As further illustrated in FIG. 3, one or more fastening elements 9 can be integrally integrated on the sound insulation layer 6. The fastening elements 9 are for example clamp-like in that they have two legs 9.1, 9.2 projecting on the outside of the sound insulation layer 6, which form an undercut recess 10 for the positive or clamping reception of cables or lines (not shown).
Des weiteren können an der Schalldämmschicht 6 auch eine oder mehrere tüllenförmige Kabeldurchführungen 11 ein¬ stückig integriert sein, denen damit fluchtende Aus¬ schnitte oder Aussparungen in Form von Durchgangs- Öffnungen 12 in der schallabsorbierende Schicht 7 zugeordnet sind. Die Kabeldurchführungen 11 sind vorzugsweise konisch ausgebildet und weisen an ihrem jeweiligen Ende mindestens zwei diametral gegenüber- liegende Axialschlitze (nicht gezeigt) auf, so dass sie sich an unterschiedliche Durchmesser von Kabeln bzw. Leitungen anpassen können und diese stets abdichtend umfassen.Furthermore, one or more sleeve-shaped cable bushings 11 may be integrally integrated on the sound insulation layer 6, which sections or recesses in the form of passage openings 12 in the sound-absorbing layer 7 are associated therewith. The cable bushings 11 are preferably conical and have at their two ends at least two diametrically opposite lying axial slots (not shown), so that they can adapt to different diameters of cables or lines and these always include sealing.
Die erfindungsgemäße Verkleidung 1 lässt sich in der Weise herstellen, dass zunächst aus einer Polyol und Isocyanat enthaltenden Mischung mit dem oben angegebenen Mischungsverhältnis die Schalldämmschicht 6 in einer durch ein Unterwerkzeug 13 und ein Oberwerkzeug 14 definierten Kavität formgeschäumt wird (Fig. 6) .The covering 1 according to the invention can be produced in such a way that the sound-deadening layer 6 is initially foam-molded in a cavity defined by a lower tool 13 and an upper tool 14 from a mixture containing polyol and isocyanate with the above-indicated mixing ratio (FIG. 6).
Der Mischung zur Herstellung der Schalldämmschicht 6 kann gegebenenfalls auch Füllstoff, vorzugsweise in Form von Bariumsulfat und/oder Kalziumcarbonat zugegeben werden.If appropriate, filler, preferably in the form of barium sulphate and / or calcium carbonate, may also be added to the mixture for producing the soundproofing layer 6.
Mindestens eines der Formwerkzeuge 13, 14 ist mit einer Heizeinrichtung (nicht dargestellt) versehen, z.B. mit im Werkzeug 13 und/oder 14 integrierten elektrischen Heiz¬ widerständen. Die Werkzeugtemperatur wird in Abhängigkeit des Mischungsverhältnisses von Isocyanat-Material und Polyol-Material so gesteuert, dass die erzeugte Schalldämmschicht 6 eine zellige Kernzone 6.1 und eine im Wesentlichen luftundurchlässige Außenhaut 6.2 aufweist (vgl. Fig. 4) . Die Rohdichte der Schalldämmschicht 6 liegt im Bereich von 0,1 bis 1,4 g/cm3, vorzugsweise im Bereich von 0,2 bis 1,1 g/cm3. Die durchschnittliche Dicke der Schalldämmschicht 6 liegt beispielsweise im Bereich von 1,5 bis 5 mm, insbesondere im Bereich von 2 bis 4 mm.At least one of the forming tools 13, 14 is provided with a heating device (not shown), eg with electrical heating resistors integrated in the tool 13 and / or 14. The mold temperature is controlled as a function of the mixing ratio of isocyanate material and polyol material so that the generated sound insulation layer 6 has a cellular core zone 6.1 and a substantially air-impermeable outer skin 6.2 (see Fig. 4). The bulk density of the sound insulation layer 6 is in the range of 0.1 to 1.4 g / cm 3 , preferably in the range of 0.2 to 1.1 g / cm 3 . The average thickness of the sound insulation layer 6 is, for example, in the range of 1.5 to 5 mm, in particular in the range of 2 to 4 mm.
Nach der Herstellung der Schalldämmschicht 6 wird das Oberwerkzeug 14 gegen ein anderes Oberwerkzeug 14' ausgetauscht, welches mit dem Unterwerkzeug 13 und der daran noch anliegenden Schalldämmschicht 6 eine neue (weitere) Kavität 15 begrenzt (Fig. 7) . In diese Kavität 15 wird zur Erzeugung der schallabsorbierenden Schicht 7 wiederum eine Polyol und Isocyanat enthaltende Mischung eingespritzt, wobei die Schicht 7 aus dem gleichen Isocyanat-Material und dem gleichen Polyol-Material her¬ gestellt wird wie die hinterschäumte Schalldämmschicht 6, jedoch mit einem unterschiedlichen Mischungsverhältnis von Isocyanat-Material und Polyol-Material. Dem Polyol oder der Mischung zur Herstellung der schallabsorbieren¬ den Schicht 7 wird optional CO2 zugegeben.After the production of the sound insulation layer 6, the upper tool 14 is exchanged for another upper tool 14 ', which with the lower tool 13 and the Sound absorbing layer 6 still attached thereto delimits a new (further) cavity 15 (FIG. 7). In this cavity 15, a polyol and isocyanate-containing mixture is injected to produce the sound-absorbing layer 7, wherein the layer 7 is made of the same isocyanate material and the same polyol material as the foam-backed sound insulation layer 6, but with a different Mixing ratio of isocyanate material and polyol material. Optionally, CO 2 is added to the polyol or the mixture for producing the sound-absorbing layer 7.
Die Rohdichte der schallabsorbierenden Schicht 7 liegt im Bereich von 0,016 bis 0,065 g/cm3, vorzugsweise im Bereich von 0,02 bis 0,06 g/cm3. Aufgrund der unter¬ schiedlichen Rohdichten von Schalldämmschicht 6 und schallabsorbierender Schicht 7 ergibt sich am Übergang der Schichten 6, 7 ein akustischer Impedanzsprung, der hinsichtlich der schallisolierenden Wirkung der erfindungsgemäßen Verkleidung 1 vorteilhaft ist.The bulk density of the sound absorbing layer 7 is in the range of 0.016 to 0.065 g / cm 3 , preferably in the range of 0.02 to 0.06 g / cm 3 . Due to the differing gross densities of sound insulation layer 6 and sound-absorbing layer 7 results in the transition of the layers 6, 7 an acoustic impedance jump, which is advantageous in terms of sound-insulating effect of the panel 1 according to the invention.
Die Dicke der schallabsorbierenden Schicht 7 kann in Abhängigkeit der akustischen Erfordernisse örtlich unterschiedlich stark ausgebildet sein (vgl. insbesondere Fig. 7) . Die Dicke der Schicht 7 liegt beispielsweise im Bereich von 10 bis 30 mm. Angrenzend an die durch die Schalldämmschicht 6 gebildete Dichtlippe 8 weist die schallabsorbierende Schicht 7 vorzugsweise einen stufen¬ förmig ausgebildeten Randbereich 16 auf (vgl. Fig. 3) .The thickness of the sound-absorbing layer 7 can be formed locally differently depending on the acoustic requirements (see in particular Fig. 7). The thickness of the layer 7 is for example in the range of 10 to 30 mm. Adjacent to the sealing lip 8 formed by the sound insulation layer 6, the sound-absorbing layer 7 preferably has a step-shaped edge region 16 (see FIG. 3).
Bei dem in Fig. 4 dargestellten Abschnitt einer erfindungsgemäßen Verkleidung sind die Schalldämmschicht 6 und die schallabsorbierende Schicht 7 unmittelbar miteinander stoffschlüssig verbunden, wobei zunächst die Schalldämmschicht β formgeschäumt wurde und anschließend die schallabsorbierende Schicht 7 durch Hinterschäumen der Schalldämmschicht 6 erzeugt wurde.In the section of a lining according to the invention shown in FIG. 4, the soundproofing layer 6 and the sound-absorbing layer 7 are instantaneous materially connected to each other, wherein first the sound insulation layer β was foamed and then the sound-absorbing layer 7 was produced by back-foaming the sound insulation layer 6.
Fig. 5 veranschaulicht eine Variante, bei der die Schall¬ dämmschicht 6 und die schallabsorbierende Schicht 5 unter Zwischenordnung einer Sperrfolie 17 aneinandergeschäumt sind. Die Sperrfolie 17 erhöht die Schalldämmwirkung der erfindungsgemäßen Verkleidung 1 und verbessert die Verbindung zwischen Schalldämmschicht 6 und schallabsorbierender Schicht 7. Vorzugsweise besteht die Sperrfolie 17 ebenfalls aus Polyurethan.FIG. 5 illustrates a variant in which the soundproofing layer 6 and the sound-absorbing layer 5 are foamed together with the interposition of a barrier film 17. The barrier film 17 increases the soundproofing effect of the lining 1 according to the invention and improves the connection between sound insulation layer 6 and sound-absorbing layer 7. Preferably, the barrier film 17 is also made of polyurethane.
Die Herstellung einer Verkleidung gemäß Fig. 5 kann in der Weise erfolgen, dass die Sperrfolie 17 unter Verwen¬ dung von Formwerkzeugen 13, 14 gemäß Fig. 6 mit der die Schalldämmschicht 6 bildenden Materialmischung hinter¬ schäumt wird. Hierzu können an der Unterseite des Oberwerkzeuges 14 eine Vielzahl kleiner Saugöffnungen (nicht gezeigt) münden, mittels denen die Sperrfolie 17 durch Saugwirkung am Oberwerkzeug 14 gehalten wird. Die schallabsorbierende Schicht 7 wird danach unter Verwen¬ dung eines anderen, eine entsprechende Kavität aufweisen¬ den Oberwerkzeuges 14' durch Hinterschäumen der Sperr¬ folie 17 erzeugt, ähnlich wie es in Fig. 7 dargestellt ist.The production of a lining according to FIG. 5 can take place in such a way that the barrier film 17 is foamed back using the molding materials 13, 14 according to FIG. 6 with the material mixture forming the sound insulation layer 6. For this purpose, a plurality of small suction openings (not shown) open at the bottom of the upper tool 14, by means of which the barrier film 17 is held by suction on the upper tool 14. The sound-absorbing layer 7 is then produced by using a different cavity, the upper tool 14 ', by foaming the barrier film 17, similar to that shown in FIG. 7.
Die Ausführung der Erfindung ist nicht auf die vorstehend beschriebenen Ausführungsbeispiele beschränkt. Vielmehr sind verschiedene weitere Varianten denkbar. So können an der Schalldämmschicht 6 beispielsweise auch bereichsweise versteifende Rippen oder dergleichen einstückig ausgeformt sein. The embodiment of the invention is not limited to the embodiments described above. Rather, various other variants are conceivable. Thus, for example, partially reinforcing ribs or the like may be integrally formed on the sound insulation layer 6.

Claims

P A T E N T A N S P R Ü C H E PATENT APPLICATIONS
1. Verfahren zur Herstellung einer leichten, schall¬ isolierenden Verkleidung (1) für ein Karosserieteil eines Kraftfahrzeuges, insbesondere in Form einer leichten Stirnwandverkleidung, bei dem unter Verwendung eines Formwerkzeuges (13, 14, 14') eine Schalldämmschicht (6) aus Polyurethanschaum mit offenzelligem Polyurethan-Weichschaum zur Ausbildung einer schallabsorbierenden Schicht (7) hinterschäumt wird oder unter Verwendung eines Formwerkzeuges (13, 14, 14' ) eine schallabsorbierende Schicht (7) aus Polyurethan-Weichschaum mit Polyurethanschaum zur Ausbildung einer Schalldämmschicht (6) hinterschäumt wird, d a d u r c h g e k e n n z e i c h n e t, dass der Polyurethan-Weichschaum aus dem gleichen Isocyanat-Material und dem gleichen Polyol-Material erzeugt wird wie der Polyurethanschaum der Schalldämmschicht (6), jedoch mit unterschiedlichem Mischungsverhältnis von Isocyanat-Material und Polyol-Material, wobei der Gewichtsanteil des Isocyanat-Materials in der Mischung zur Herstellung der Schalldämmschicht (6) größer eingestellt wird als in der Mischung zur Herstellung der schallabsorbierenden Schicht (7), so dass die Schalldämmschicht (6) eine im Wesentlichen luftundurchlässige Außenhaut (6.2) und eine höhere Rohdichte aufweist als die erzeugte schallabsorbierende Schicht (7) . 1. A method for producing a lightweight, sound-insulating cladding (1) for a body part of a motor vehicle, in particular in the form of a light end wall cladding, in which using a molding tool (13, 14, 14 ') a sound insulation layer (6) made of polyurethane foam Open-cell flexible polyurethane foam for forming a sound-absorbing layer (7) is back-foamed or using a mold (13, 14, 14 ') a sound-absorbing layer (7) made of flexible polyurethane foam with polyurethane foam to form a sound insulation layer (6) is back-foamed, characterized in that the flexible polyurethane foam is produced from the same isocyanate material and the same polyol material as the polyurethane foam of the soundproofing layer (6), but with a different mixing ratio of isocyanate material and polyol material, wherein the weight fraction of the isocyanate material in the mixture for making the scarf Insulation layer (6) is set larger than in the mixture for producing the sound-absorbing layer (7), so that the sound insulation layer (6) has a substantially air-impermeable outer skin (6.2) and a higher density than the generated sound-absorbing layer (7).
2. Verfahren nach Anspruch 1, d a d u r c h g e k e n n z e i c h n e t, dass das Mischungsverhältnis zur Herstellung des Polyurethanschaums für die Schalldämmschicht (6) so eingestellt wird, dass 100 Gew.-% Polyol mit etwa 60 bis 70 Gew.-% Isocyanat vermischt werden, wohingegen das Mischungsverhältnis zur Herstellung des Polyurethan-Weichschaums für die schallabsorbierende Schicht (7) so eingestellt wird, dass 100 Gew.-% Polyol mit etwa 45 bis 55 Gew.-% Isocyanat vermischt werden.2. The method according to claim 1, characterized in that the mixing ratio for producing the polyurethane foam for the sound insulation layer (6) is adjusted so that 100 wt .-% polyol with about 60 to 70 wt .-% isocyanate are mixed, whereas the mixing ratio to Preparation of the flexible polyurethane foam for the sound-absorbing layer (7) is adjusted so that 100 wt .-% polyol with about 45 to 55 wt .-% isocyanate are mixed.
3. Verfahren nach Anspruch 1 oder 2, d a d u r c h g e k e n n z e i c h n e t, dass das Mischungsverhältnis zur Herstellung des Polyurethanschaums für die Schalldämmschicht (6) so eingestellt wird, dass 100 Gew.-% Polyol mit etwa 63 bis 68 Gew.-%, insbesondere mit etwa 65 Gew.-% Isocyanat vermischt werden.3. The method according to claim 1 or 2, characterized in that the mixing ratio for the preparation of the polyurethane foam for the sound insulation layer (6) is adjusted so that 100 wt .-% polyol with about 63 to 68 wt .-%, in particular with about 65 wt .-% isocyanate are mixed.
4. Verfahren nach einem der Ansprüche 1 bis 3, d a d u r c h g e k e n n z e i c h n e t, dass das Mischungsverhältnis zur Herstellung des Polyurethan-Weichschaums für die schallabsorbierende Schicht (7) so eingestellt wird, dass 100 Gew.-% Polyol mit etwa 48 bis 53 Gew.-%, insbesondere mit etwa 50 Gew.-% Isocyanat vermischt werden.4. The method according to any one of claims 1 to 3, characterized in that the mixing ratio for producing the flexible polyurethane foam for the sound-absorbing layer (7) is adjusted so that 100 wt .-% polyol with about 48 to 53 wt .-%, especially with about 50 wt .-% isocyanate are mixed.
5. Verfahren nach einem der Ansprüche 1 bis 4, d a d u r c h g e k e n n z e i c h n e t, dass dem Polyol oder der Mischung zur Herstellung des Polyurethan-Weichschaums für die schallabsorbierende Schicht (7) CO2 zugegeben wird.5. The method according to any one of claims 1 to 4, characterized in that is added to the polyol or the mixture for producing the flexible polyurethane foam for the sound-absorbing layer (7) CO 2 .
6. Verfahren nach einem der Ansprüche 1 bis 5, d a d u r c h g e k e n n z e i c h n e t, dass der Mischung zur Herstellung der Schalldämmschicht6. Method according to one of claims 1 to 5, characterized in that the mixture for producing the sound insulation layer
(6) Füllstoff, vorzugsweise in Form von Bariumsulfat und/oder Kalziumcarbonat zugegeben wird.(6) filler, preferably in the form of barium sulfate and / or calcium carbonate is added.
7. Verfahren nach einem der Ansprüche 1 bis 6, d a d u r c h g e k e n n z e i c h n e t, dass eine Seite einer Sperrfolie (17) mit dem die Schalldämmschicht (6) bildenden Polyurethanschaum und die andere Seite der Sperrfolie (17) mit dem die schallabsorbierende Schicht (7) bildenden Polyurethan-Weichschaum hinterschäumt wird.7. The method according to any one of claims 1 to 6, characterized in that one side of a barrier film (17) with the sound insulation layer (6) forming polyurethane foam and the other side of the barrier film (17) with the sound-absorbing layer (7) forming polyurethane Soft foam is backfoamed.
8. Verfahren nach Anspruch 7, d a d u r c h g e k e n n z e i c h n e t, dass als Sperrfolie (17) eine Sperrfolie aus Polyurethan verwendet wird.8. The method according to claim 7, characterized in that a barrier film made of polyurethane is used as the barrier film (17).
9. Verfahren nach einem der Ansprüche 1 bis 8, d a d u r c h g e k e n n z e i c h n e t, dass die Schalldämmschicht (6) partiell mit Polyurethan- Weichschaum hinterschäumt wird, derart, dass die Schalldämmschicht (β) am Rand der Verkleidung (1) eine flexible Dichtlippe (8) bildet.9. Method according to one of claims 1 to 8, characterized in that the sound insulation layer (6) is partially backfoamed with flexible polyurethane foam such that the sound insulation layer (β) forms a flexible sealing lip (8) at the edge of the lining (1).
10. Verfahren nach einem der Ansprüche 1 bis 9, d a d u r c h g e k e n n z e i c h n e t, dass die Schalldäiranschicht (6) derart geschäumt wird, dass daran ein oder mehrere Befestigungselemente (9) einstückig integriert sind.10. The method according to any one of claims 1 to 9, characterized in that the Schalldäiranschicht (6) is foamed such that one or more fasteners (9) are integrally integrated thereon.
11. Schallisolierende Verkleidung (1) für ein Karosserieteil eines Kraftfahrzeuges, insbesondere in Form einer leichten Stirnwandverkleidung, mit einer formgeschäumten Schalldämmschicht (6) aus Polyurethanschaum und einer formgeschäumten schallabsorbierenden Schicht (7) aus offenzelligem Polyurethan-Weichschaum, wobei die Schalldämmschicht (6) und die schallabsorbierende Schicht (7) aneinandergeschäumt sind, d a d u r c h g e k e n n z e i c h n e t, dass die Schalldämmschicht (6) aus dem gleichen Isocyanat-Material und dem gleichen Polyol-Material hergestellt ist wie die schallabsorbierende Schicht11. Sound-insulating cladding (1) for a body part of a motor vehicle, in particular in the form of a light end wall cladding, with a mold-foamed Schalldämmschicht (6) of polyurethane foam and a mold-foamed sound-absorbing layer (7) of open-cell flexible polyurethane foam, wherein the sound insulation layer (6) and the sound-absorbing layer (7) are foamed together, characterized in that the sound-absorbing layer (6) is made of the same isocyanate material and the same polyol material as the sound-absorbing layer
(7), jedoch mit unterschiedlichem Mischungsverhältnis von Isocyanat-Material und Polyol-Material derart, dass die Schalldämmschicht(7), but with different mixing ratio of isocyanate material and polyol material such that the sound insulation layer
(6) eine höhere Rohdichte aufweist und härter ist als die schallabsorbierende Schicht (7), wobei die Schalldämmschicht (6) eine im Wesentlichen luftundurchlässige Außenhaut (6.2) aufweist.(6) has a higher bulk density and is harder than the sound-absorbing layer (7), wherein the sound-absorbing layer (6) has a substantially air-impermeable outer skin (6.2).
12. Verkleidung nach Anspruch 11, d a d u r c h g e k e n n z e i c h n e t, dass die Schalldämmschicht (6) eine Rohdichte im Bereich von 0,1 bis 1,4 g/cm3 aufweist, während die schallabsorbierende Schicht (7) eine Rohdichte im Bereich von 0,016 bis 0,065 g/cm3 aufweist.12. Cladding according to claim 11, characterized in that the sound insulation layer (6) has a bulk density in the range of 0.1 to 1.4 g / cm 3 , while the sound-absorbing layer (7) has a bulk density in the range of 0.016 to 0.065 g / cm 3 .
13. Verkleidung nach einem der Ansprüche 11 bis 12, d a d u r c h g e k e n n z e i c h n e t, dass die Schalldämmschicht (6) eine Rohdichte im Bereich von 0,2 bis 1,1 g/cm3 aufweist.13. Panel according to one of claims 11 to 12, characterized in that the sound insulation layer (6) has a bulk density in the range of 0.2 to 1.1 g / cm 3 .
14. Verkleidung nach einem der Ansprüche 11 bis 13, d a d u r c h g e k e n n z e i c h n e t, dass die schallabsorbierende Schicht (7) eine Rohdichte im Bereich von 0,02 bis 0,06 g/cm3 aufweist.14. Cladding according to one of claims 11 to 13, characterized in that the sound-absorbing layer (7) has a bulk density in the range of 0.02 to 0.06 g / cm 3 .
15. Verkleidung nach einem der Ansprüche 11 bis 14, d a d u r c h g e k e n n z e i c h n e t, dass die schallabsorbierende Schicht (7) durch Hinterschäumung der Schalldämmschicht (6) unmittelbar mit der Schalldämmschicht (6) verbunden ist.15. Cladding according to one of claims 11 to 14, characterized in that the sound-absorbing layer (7) is connected by back-foaming of the sound insulation layer (6) directly to the sound insulation layer (6).
16. Verkleidung nach einem der Ansprüche 11 bis 14, d a d u r c h g e k e n n z e i c h n e t, dass die Schalldämmschicht (6) und die schallabsorbierende Schicht (7) unter Zwischenordnung einer Sperrfolie (17) aneinandergeschäumt sind.16. Cladding according to one of claims 11 to 14, characterized in that the sound insulation layer (6) and the sound-absorbing layer (7) are foamed together with the interposition of a barrier film (17).
17. Verkleidung nach Anspruch 16, d a d u r c h g e k e n n z e i c h n e t, dass die Sperrfolie (17) aus Polyurethan hergestellt ist.17. Cladding according to claim 16, characterized in that the barrier film (17) is made of polyurethane.
18. Verkleidung nach einem der Ansprüche 11 bis 17, d a d u r c h g e k e n n z e i c h n e t, dass die Schalldämmschicht (6) am Rand der Verkleidung18. Cladding according to one of claims 11 to 17, characterized in that the sound insulation layer (6) at the edge of the cladding
(1) eine flexible Dichtlippe (8) bildet.(1) forms a flexible sealing lip (8).
19. Verkleidung nach einem der Ansprüche 11 bis 18, d a d u r c h g e k e n n z e i c h n e t, dass an der Schalldämmschicht (6) ein oder mehrere Befestigungselemente (9) und/oder eine oder mehrere tüllenförmige Kabeldurchführungen (11) einstückig integriert sind.19. Panel according to one of claims 11 to 18, characterized in that one or more fastening elements (9) and / or one or more sleeve-shaped cable bushings (11) are integrally integrated on the sound insulation layer (6).
20. Verkleidung nach einem der Ansprüche 11 bis 19, d a d u r c h g e k e n n z e i c h n e t, dass sie ein Gesamtflächengewicht von weniger als 1000 g/m2 aufweist. 20. Panel according to one of claims 11 to 19, characterized in that it has a total basis weight of less than 1000 g / m 2 .
EP05810923A 2004-11-11 2005-11-10 Light-weight sound-absorbing covering for a body part of a motor vehicle and method for producing the same Not-in-force EP1809460B1 (en)

Applications Claiming Priority (2)

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DE102004054646A DE102004054646B4 (en) 2004-11-11 2004-11-11 Lightweight sound-insulating panel for a body part of a motor vehicle and method for its production
PCT/EP2005/012078 WO2006050961A1 (en) 2004-11-11 2005-11-10 Light-weight sound-absorbing covering for a body part of a motor vehicle and method for producing the same

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EP1809460B1 EP1809460B1 (en) 2010-05-26

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JP (1) JP2008519704A (en)
KR (1) KR20070086032A (en)
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CN101056750A (en) 2007-10-17
KR20070086032A (en) 2007-08-27
ATE468957T1 (en) 2010-06-15
DE502005009654D1 (en) 2010-07-08
DE102004054646B4 (en) 2008-12-04
WO2006050961A1 (en) 2006-05-18
EP1809460B1 (en) 2010-05-26
DE102004054646A1 (en) 2006-06-01

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